Beaded article

ABSTRACT

A beaded article having a support layer on which a bottom layer and a top layer of sheet material are superimposed. The top layer is heat bonded to the bottom layer and both are heat bonded to the support layer along a circumferentially complete narrow annular zone. In the area circumscribed by the annular zone the top layer is provided with a raised self-supporting bead-like prominence which contains ornamental particles visible to a viewer because the top layer is of transparent material.

Unlted States Patent 11 1- 1111 ,855,043 Kuroda Dec. 17, 1974 1 BEADED ARTICLE 2,710,046 6/1955 Markus et al. 161/40 1 2,726,941 12/1955 Markus et a1... 161/218 X [75] Inventor: *Mlmru Kumda Hyogoken Japan 2,729,010 l/l956 Markus et a1... 161/39 x 731 Assignees: Nishizawa Shoji Co. Ltd., Osaka, g mc o i fi x fag i 3,142,599 7/1964 Chavannes... 156/210 6W 2,592,882 4 1952 Fisher et al. l61/DlG. 5 York Part Interest to each 2,806,509 9/1957 BOZZZICCO et al 161 162 x 22] i July 7 1972 3,388,027 6/1968 Altman l6l/6 X 3,723,232 3/1973 Heller 161/DlG. 5 [21] Appl. No.: 269,563 3,726,755 4/1973 Shannon l6l/DIG. 5

Related US. Application Data FOREIGN PATENTS OR APPLICATIONS [60] Con inuation of Ser. N01 80,385, Oct. 13, 1970, 943,511 12/1963 Great Britain 161/119 abandoned, which is a i n of r. 8 8,128 950,262 2/1964 Great Britain 161/2 March 18, 1969, abandoned, which is a iggg gzgggggg of Primary ExaminerGeorge P. Lesmes Assistant Examiner-Henry F. Epstein 52 U.S. c1 161/5, 161/45, 161/127, Ammey Smker 161/138, 161/162, 161/164, 161/168, 161/413 [51] Int. Cl. B29c 3/00, B32b 3/00 [57] ABSTRACT [58] gs 35 2 A beaded article having a support layer on which a 3 DIG g g 5 8/ bottom layer and a top layer of sheet material are su- 219 perimposed. The top layer is heat bonded to the bottom layer and both are heat bonded to the support layer along a circumferentially complete narrow annu- [56] References cued lar zone. In the area circumscribed by the annular UNITED STATES PATENTS zone the top layer is provided with a raised self- 3,256,131 6/1966 Koch et al. 156/209 X supporting bead-like prominence which contains orna- 2,693,22 1/1 5 Lyijynen 156/209 mental particles visible to a viewer because the top 2.l06,943 2/l938 Fischer layer is of transparent materiaL I 2,353,995 7/1944 Conner l6l/5. 2,582,132 1/1952 Kaphan 161/40 7 Claims, 8 Drawing Figures O 0 O O o o O o o o 0 '0 o o 0 o 0 o 2 0 0 0 o O o o o o O o oO o O o O o o Q o o 0 O o o o O o o 0 e O o O o 00 o o o 0 0 o o 0 OC) 0 O o o O 0 O O Q o 0 0 0 0 O o o O 0 0 0 O o O o o o O O O O o o 00 000 PATEHTEI] DEC 1 7 I974 snmm g;

ATTORNEY 1 BEADED ARTICLE CROSS-REFERENCE TO RELATED APPLICATIONS The present application is a continuation of application Ser. No. 80,385, filed Oct. 13, I970, now abandoned, which was a division of my copending application, Ser. No. 808,128, (now abandoned) filed on Mar. 18, I969, which in turn is a continuation-in-part of copending application, Ser. No. 662,962, (now abandoned) filed on Aug. 24, I967 and entitled METHOD AND APPARATUS FOR FORMING APPLIQUE DE- SIGNS.

BACKGROUND OF THE INVENTION The present invention relates generally to beads, and more particularly to a beaded article.

In my aforementioned copending application Ser. No. 661,962, I have disclosed a raised padded applique, as well as a method and apparatus for making such an applique. As there pointed out, such an applique can be made by superimposing two layers of material, sandwiching a layer of padding material between them, and bonding the two layers together across the intermediate layer of padding material along a circumferentially complete narrow annular zone. The applique will then appear on one layer as a raised padded design.

My deliberations have shown that I am able to make an article having a beaded appearance, by again resorting to the use of bondable sheet material. My application Ser. No. 803,128 is directed to a method of making such an article and the present invention is concerned with the novel article itself.

SUMMARY OF THE INVENTION It is, accordingly, a general object of the present invention to provide a beaded article.

In pursuance of the above objects, and others which will become apparent hereafter, one feature of my invention resides in a beaded article of the type under discussion I superimpose upon a base an assembly comprising a top and a bottom layer of sheet material with spacing or ornamental means therebetween. At least the top layer consists of a plastically flowable material. I thereupon press the top layer against the bottom layer and the base in a circumferentially complete narrow annular zone while I maintain the top layer spaced from the bottom layer in the area which is circumscribed by the annular zone. While the pressure is in effect, I heatbond the layers to one another as well as to the base in the aforementioned circumferentially complete narrow annular zone and simultaneously cause the top layer to undergo plastic flowing inwardly of the annular zone as well as in direction away from the bottom layer. This results in the formation of a raised self-supporting bead-like prominence in the aforementioned area of the top layer.

Advantageously the top layer will be a lighttransmitting sheet material, particularly a synthetic plastic material, and I prefer that the top layer be a transparent plastic material. The bottom layer may also be a transparent plastic material and may, but need not be capable of plastic flowing. The spacing means or ornamental means is advantageously in form of discrete particles having an ornamental appearance that is being colored, light-reflecting or the like, and they will be visible in the interior of the bead-like prominence providing a desired appearance tothe same. Of course, the base may be of any desired suitable material, for instance a textile material such as a'dress, an other garment or the like,to which one or, usually, more than one of the bead-like prominences are to be affixed. The assembly may also be unitary, with the particles previously embedded between the top and bottom layers.

By resorting to my novel intention I obtain an article wherein large or small numbers of such bead-like prominences may be affixed simultaneously, and it goes without saying that they may be arranged in any desired pattern, as will be discussed in more detail below. By contrast it should be pointed out that the affixing of conventional beads to an article is to this day carried out by hand and individually, with the result that articles which are beaded in the customary manner are very expensive because of the manual labor involved.

It should be further pointed out that an article according to my present invention has the bead-like prominences affixed thereto permanently so that they will not separate regardless of whether the article is washed, dry-cleaned, wetted or the like. The simulated beads provided in accordance with my present invention have permanent brightness because the ornamental particles are protected in the interior of the respective bead-like prominence. Furthermore, an article provided with beading in this manner is light because the weight of the individual bead-like constructions is considerably less than that of conventional beads.

It is also evident that beading of this type may be provided not only on garments or the like, but also on wallpaper, furniture, other types of wall coverings, or in fact almost any type of base, including textile materials plastics, leather, glass, wood and the like. In fact, such beading may even be provided on a metallic base if def sired.

The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be vest understood from the following description of specific embodiments when read in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a fragmentary somewhat diagrammatic plan view of a beaded article made in accordance with the present invention;

FIG. 2 is a fragmentary elevation showing a bead according to the present invention being formed by a single die;

FIG. 3 is a view similar to FIG. 1, but illustrating the die used for making the article shown in FIG. 1;

FIG. 4 is a side-elevational view of FIG. 3;

FIG. 5 is a section taken on the line V-V of FIG. 3;

FIG. 6 is a view similar to FIG. 5 but illustrating an other embodiment;

FIG. 7 is a diagrammatic partly sectioned view illustrating a further embodiment of the die; and

FIG. 8 is a view similar to FIG. 7 but illustrating yet another embodiment of the die.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Discussing now the drawing in detail, and firstly FIGS. 1 and 2 thereof, it will be seen that I have illustrated in FIG. 1 a beaded article which here shall be assumed to consist of a textile base layer 1 on which I have superimposed a discrete bottom layer 3 and a discrete top layer 4 which may both be gas-impermeable. In the illustrated embodiment both the top layer 4 and the bottom layer 3 consist of synthetic plastic materials for instance polyvinyl chloride, although it will be ap' preciated that they need not be of the identical material. Spacing means is interposed between the layers 2, 3 and 4, and this is here illustrated (compare FIG. 2) as a layer 6 consisting of a plurality of discrete particles 6, as clearly shown in FIG. 2. The particles 6 are brightly colored and may be fine slivers of polyester, nylon or the like, but it should be understood that other materials are similarly suitable. The sheet 4 in the illustrated embodiment is transparent, preferably clear, so that the particles 6 are visible. A support 16 is provided inform of a table, plate or the like on which the layers 1, 3, 4 and 6' are temporarily supported. At least one of the layers 3 or 4 is heat-bondable and capable of plastic flowing when exposed to the requisite conditions.

1 provide a mold which will be discussed in further detail with reference to FIGS. 3 and 4 and which is provided with as many mold portions as beads or bead-like prominences as they might more properly be called are to be provided. These prominences are identified with reference numeral 2 and may be distributed, as shown in FIG. 1, in any desired manner, order or pattern.

' Each of the mold portions which is operative for making one of the prominences 2 is of the general type shown in FIG. 2 in that it is provided with a recess whose open end is surrounded by a cutting and pressure edge 13 to which there is inwardly adjacent a beveled shoulder 14.

To make an article of the type under discussion and shown in FIG. 1, an assembly consisting ofthe layers 3, 4 and 6 is superimposed upon the support layer 1 and the total assembly is rested on the plate or table 16. There upon the die is moved downwardly in the direction ofthe arrow X shown in FIG. 2 so that the cutting and pressure edge 13 engages a circumferentially complete narrow annular zone of the assembly, pressing the layers 4 and 6 against the layer 3 and all of them against the support layer 1. This results in the inclusion of an area of the top layer 4 within the recess 15, this area being normally circular but which may also be of otherthan-circular outline. Simultaneously the mold is heated as will be discussed below, and this results in the present embodiment in heat-bonding of the layers 3 and 4 to one another as well as to the base or support layer 1. Such bonding takes place along the circumferentially complete narrow annular zone corresponding to the cutting and pressure face 13, it being understood that at least the layer 4, and generally the layers 3 and 4, consist of thermoplastic material. Because of the beveled shoulder 14 the material of the bead-like prominence 2 which is being produced is of but little changed thickness in the region 9, that is the region below the beveled shoulder 14. The region below the cutting and pressure face 13. however. is melted and drastically reduced in thickness, as evident from FIG.

2. This results in severing of the portions 4, 6' and 3' of the respective layers 4, 6 and 3 from the portions located within the confines of the die. The air entrapped between the layers 3 and 4 in the pockets existing between the individual particles of the layer 6 expands as a result of the heat-bonding of the layers 1, 3 and 4 and results in plastic deformation of the layer 4 within the confines of the recess 15 in direction radially inwardly from the narrow annular zone 8'-in which the layers are bonded together-as well as in direction away from the bottom layer 3 and deeper into the recess 15. The result is a hollow self-supporting bead-like prominence 2 which, because of its dome-shape and because of the inherent resistance of the material of the layer 4 to deformation, is capable of withstanding stresses tending to collapse it when the air in its interior cools and has its expansion reversed. The formation of the prominence 2 may be aided by proper selection of the bevel of the shoulder 14, serving, when pressure is exerted in the manner shown in FIG. 2 in the direction of the arrow X, to initiate plastic flowing of the material ofthe layer 4 radially inwardly and in direction deeper into the recess 15. In fact, bonding of a type other than heat-bonding is conceivable and it is also conceivable that by proper configuration of the beveled shoulder 14, the prominence 2 could be provided without the aid of expanding air simply as a result of plastic flowing of the material of the layer 4 resulting from pressure exerted on it by the die.

It will be appreciated that in FIG. 2 only a portion of the die used for FIG. 1 has been illustrated, and that the analogous process takes place simultaneously for all of the various prominences 2 which are shown in FIG. 1. This can, of course, be done sequentially but preferably it is done simultaneously, with the die being configurated accordingly, as will be discussed. When the article is completed and the various prominences are provided as shown in FIG. 1, the die is withdrawn in direction opposite the arrow X in FIG. 2, and the severed remainders 3, 4' and 6' of the layers 3, 4 and 6 may be peeled away, thus leaving only the prominences 2 attached to the support or base layer 1. The cutting edge along which the severing occurs is identified with reference numeral 7 in FIG. 2.

Coming now to FIGS. 3 and 4 it will be seen therein that I have rather diagrammatically illustrated a die for making the article shown in FIG. I. It will be seen that in this embodiment the die comprises base means 10 in form ofa platen provided with wall means 11 having an exposed face 12a. In the illustrated embodiment the wall means 11 is constituted by a plurality of tubular mold portions 12 of the configuration shown for instance in FIGS. 2, 5 and 6 and arranged in a pattern P. The free end faces of these mold portions 12 together constitute the exposed face 12a and, as shown in FIG. 2 for example, the exposed face 12a is provided with a plurality of recesses 15 extending inwardly. Suitable heating means 10a is provided connected with the platen 10 for heating the same and thereby the wall means 11.

As shown in FIG. 5, which is the section taken on the line V\/ of FIG. 3, the tubular wall means may be provided in form ofa plurality of pins 12 each of which is received in a bore 10b provided in the base means 10 and rigidly retained therein, for instance by a weld 100. The distance to which each of the pins 12 projects from the base means 10 is identified with reference numeral H and it will be seen that the free end faces of each of the pins 12 are located, as illustrated by the dimension H, in a common plane which is the exposed face 12a of the wall means 11. Reference numerals 13, 14 and 15 identify features which have already been discussed with respect to FIG. 2.

FIG. 6 differs from FIG. 5 only in that it illustrates that the respective pins 12 need not fill the bores b in the member 10, but can also be shorter. Evidently the bores 10b themselves could be of lesser depth in this case.

The heating means illustrated may be of conventional type, and is well known in the art. In fact, it has been discussed in some more detail in my copending application Ser. No. 662,962 to which reference may be had.

The embodiment in FIG. 7 illustrates-that instead of the tubular wall means the base means which is here identified with reference numeral 70 may be provided with wall means 71 having recesses 72 whose configuration corresponds to that of the recesses provided in FIG. 5. The cutting edges and the beveled shoulders are the same and are therefore not specifically identified with reference numerals. In the embodiment of FIG. 7 the recesses extend through the entire thickness of the wall means 71. FIG. 8, on the other hand, shows that the recesses 80 need not extend over the entire thickness of the wall means 71 carried by the base means 70, but can be of such a depth as onlyto allow the desired height of the prominences 2 to be formed. In other words, whereas the recesses 72 are higher than necessary for the formation of the prominences 2, the recesses 80 in FIG. 8 need be only of such height that the prominences 2 can just form.

It will be appreciated, of course, that where the tubular wall means of the type shown in FIG. 4, for instance, is provided. all of the individual tubular members must extend in parallelism with one another.

The interior of the prominences 2 is only partially filled. in the case of the embodiment shown in FIG. 2, with the ornamental particles of the layer 6. It is emphasized that if these ornamental particles are made from certain materials such as polyester, nylon or the like. they will adhere electrostatically to the inside of the wall forming the respective prominence 2, and this assures that they are readily visible and provide the desired visual effect. If the assembly is unitary, the interior of prominences 2 may not be hollow at all.

Resort to my present invention results in the provision of bead-like prominences of strictly uniform configuration and strictly uniform type. Evidently, as many or as few of the prominences 2 as desired may be provided in a single operation, and thus my novel invention is particularly suitable for mass production at low cost, but is also capable of being used for individual production of one or a few of the prominences 2 at a time.

It is also emphasized that different sizes and shapes may be selected for the prominences, so that these need not be circular but can also be oval, rectangular, or in fact of a great variety of different shapes. Evidently, the single die may be provided with means for producing two or more different-shaped prominences at the same time. Also. it is possible to provide continuous sheets or strips of base or support material with the prominences 2, and in this case the pattern will recur at intervals which are determined by the size of the mold being used. Naturally, there is no limit on the type of pattern which may be provided, and this may be accomplished either by providing a single die with the desired pattern, or utilizing a die capable of producing one or only a few of the prominences 2 at a time and moving the die and/or the support or base material in such a manner as to obtain the pattern by repeated use of the die.

It is still emphasized that the provision of the individual particles of the layer 6 results in random scattering of light impinging on these particles through the portion of the layer 4 which constitutes the respective dome-shaped prominence 2, and this increases the brilliance of the prominences several times when direct light impinges upon them. The individual bead-like prominences are water-proof so that water cannot enter into them. Individual ones of the prominences 2 may be spaced as closely as 1 mm and as many as 2,500 or even more individual prominences 2 may be produced at one and the same time. The versatility of my invention will thus be obvious.

Evidently, it is possible to provide the desired pattern of prominences 2 not on a garment or the like, but on a patch which need not be of textile material, and which can then be suitably fixed to an article on which it is desired, for instance by sewing, by use of an adhesive of the like.

It will be understood that each of the elements described above, or two or more together, may also find a useful employment in other types of applications differing from the types described above.

While the invention has been illustrated and described as embodied in a beaded article it is not intended to be limited to the details shown, since various modification and structural changes may be made without departing in any way from the spirit of the present invention.

What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims:

1. A beaded article, comprising, in combination, a support; a plurality of spaced-apart discrete beads, each bead comprising a bottom layer of synthetic plastic sheet material superimposed upon said support and a top layer of light-transmitting synthetic plastic sheet material on said bottom layer and unitary therewith at least along a narrow circumferentially complete annular zone coinciding with the marginal zones of said layers, said layers being adhered to one another and to said support along said narrow annular zone by a heatwelded seam, and said top layer having within the confines of said zone a hollow self-supporting bead-like prominence; and particulate matter confined and visible within said bead-like prominence at least partly filling the same.

2. An article as defined in claim 1, wherein at least the material of said top layer is a thermoplastic material.

3. An article as defined in claim 2, wherein said thermoplastic material is polyvinylchloride.

4. An article as defined in claim 1, wherein said support is a textile material.

5. An article as defined in claim 1, wherein said beadlike prominence is substantially dome-shaped.

6. An article as defined in claim 1, wherein said beadlike prominence contains a quantity of entrapped air confined therein together with said particulate matter.

7. An article as defined in claim 6, wherein said layers are gas-impermeable.

EFQ'IEB S'EAIES PATENT OFFICE QERTIFICATE OF CORRECTION PA'IEH NO. 3,855,043

UATEiF Dec. 17, 1974 ENV'FHYORQ" Minoru Kuroda 2t is t rtztzed Mr wear; it: the ;:t:t ve---|dent1fied patent and that said Letters Patent nea it) am' 'ecte t as Show wow On the cover sheet [30] the following should be inserted:

- Foreign Application Priority Data December 19, 1966 Japan... 41/83085 December 19, 1966 Japan..................... 41/115532 December 19, 1966 Japan........ 41/115533 December 19, 1966 Japan 41/115535 Signcd and Sealed this twenty-second Day Of July 1975 [SEAL] A ttesr: 

1. A BEADED ARTICLE, COMPRISING, IN COMBINATION, A SUPPORT; A PLURALITY OF SPACED-APART DISCRETE BEADS, EACH BEAD COMPRISING A BOTTOM LAYER OF SYNTHETIC PLASTIC SHEET MATERIAL SUPERIMPOSED UPON SAID SUPPORT AND A TOP LAYER OF LIGHT-TRANSMITTING SYNTHETIC PLASTIC SHEET MATERIAL ON SAID BOTTOM LAYER AND UNITARY THEREWITH AT LEAST ALONG A NARROW CIRCUMFERENTIALLY COMPLETE ANNULAR ZONE COINCIDING WITH THE MARGINAL ZONES OF SAID LAYERS, SAID LAYERS BEING ADHERED TO ONE ANOTHER AND TO SAID SUPPORT ALONG SAID NARROW ANNULAR ZONE BY A HEAT-WELDED SEAM, AND SAID TOP LAYER HAVING WITHIN THE CONFINES OF SAID ZONE A HOLLOW SELF-SUPPORTING BEAD-LIKE PROMINENCE; AND
 2. An article as defined in claim 1, wherein at least the material of said top layer is a thermoplastic material.
 3. An article as defined in claim 2, wherein said thermoplastic material is polyvinylchloride.
 4. An article as defined in claim 1, wherein said support is a textile material.
 5. An article as defined in claim 1, wherein said bead-like prominence is substantially dome-shaped.
 6. An article as defined in claim 1, wherein said bead-like prominence contains a quantity of entrapped air confined therein together with said particulate matter.
 7. An article as defined in claim 6, wherein said layers are gas-impermeable. 